Heat exchanger plate for battery pack

Abstract

A heat exchanger plate, for thermal management of one or more battery packs, includes a base plate including a first core material and a lower coating layer. A channel plate is disposed adjacent to the base plate, the channel plate including at least one channel formed therein and a second core material different from the first core material. The base plate and channel plate combine to define an inlet, an outlet, and a conduit for propagating heat transfer fluid. The first core material is stronger than the second core material and the lower coating layer enhances brazing of the base plate to the channel plate. A related battery unit includes a battery pack and the heat exchanger plate. A related method includes forming the base plate and channel plate, brazing the base plate to the channel plate, and propagating heat transfer fluid between the inlet and outlet via the conduit.

What is claimed: 
     
         1 . A heat exchanger plate for thermal management of one or more battery packs, the heat exchanger plate comprising:
 a base plate comprising a first core material and a lower coating layer that coats the first core material; and   a channel plate disposed adjacent to the base plate, the channel plate comprising at least one channel formed therein and a second core material different from the first core material,   wherein the base plate and channel plate combine to define an inlet, an outlet, and a conduit for propagating heat transfer fluid between the inlet and the outlet, and   wherein the first core material is stronger than the second core material and the lower coating layer enhances brazing of the base plate to the channel plate.   
     
     
         2 . The heat exchanger plate according to  claim 1 , wherein the first core material is an aluminum alloy. 
     
     
         3 . The heat exchanger plate according to  claim 2 , wherein the first core material is a 6xxx alloy. 
     
     
         4 . The heat exchanger plate according to  claim 3 , wherein the second core material is an aluminum alloy. 
     
     
         5 . The heat exchanger plate according to  claim 4 , wherein the second core material is a 3xxx alloy. 
     
     
         6 . The heat exchanger plate according to  claim 2 , wherein the lower coating layer comprises an aluminum alloy. 
     
     
         7 . The heat exchanger plate according to  claim 6 , wherein the lower coating layer is formed from a 3xxx alloy and zinc. 
     
     
         8 . The heat exchanger plate according to  claim 6 , wherein the lower coating layer is formed from a 7072 alloy. 
     
     
         9 . The heat exchanger plate according to  claim 6 , wherein the lower coating layer is formed from a 1050 alloy. 
     
     
         10 . The heat exchanger plate according to  claim 1 , further comprising:
 a support plate disposed adjacent to the channel plate,   wherein the support plate includes a core formed from the first core material and an upper coating layer that coats the core.   
     
     
         11 . The heat exchanger plate according to  claim 10 , wherein the upper coating layer enhances brazing of the base plate to the channel plate. 
     
     
         12 . The heat exchanger plate according to  claim 11 , wherein the upper coating layer comprises an aluminum alloy. 
     
     
         13 . The heat exchanger plate according to  claim 10 , wherein the upper coating layer comprises an adhesive. 
     
     
         14 . The heat exchanger plate according to  claim 1 , wherein the battery packs are for a hybrid or electric vehicle. 
     
     
         15 . A battery unit for a hybrid or electric vehicle, the battery unit comprising:
 a battery pack; and   a heat exchanger plate for thermal management of the battery pack, the heat exchanger plate comprising:
 a base plate comprising a first core material and a lower coating layer that coats the first core material; and 
 a channel plate disposed adjacent to the base plate, the channel plate comprising at least one channel formed therein and a second core material different from the first core material; 
 wherein the base plate and channel plate combine to define an inlet, an outlet, and a conduit for propagating heat transfer fluid between the inlet and the outlet, 
 wherein the first core material is stronger than the second core material and the lower coating layer enhances brazing of the base plate to the channel plate. 
   
     
     
         16 . The battery pack according to  claim 15 , wherein the first core material is an aluminum alloy. 
     
     
         17 . The battery pack according to  claim 16 , wherein the first core material is a 6xxx alloy. 
     
     
         18 . The battery pack according to  claim 16 , wherein the lower coating layer comprises an aluminum alloy. 
     
     
         19 . The battery pack according to  claim 15 , further comprising:
 a support plate disposed adjacent to the channel plate;   wherein the support plate includes a core formed from the first core material and an upper coating layer that coats the core.   
     
     
         20 . A method comprising:
 providing a first core material and coating the first core material with a lower coating layer to form a base plate; and   providing a second core material different from the first core material, the first core material being stronger than the second core material, to form a channel plate with at least one channel disposed therein, wherein the lower coating layer enhances brazing of the base plate to the channel plate;   brazing the base plate to the channel plate, wherein the base plate and channel plate combine to define an inlet, an outlet, and a conduit; and   propagating heat transfer fluid between the inlet and outlet via the conduit.